Basic Engine 4-CYL: Other Saab 9-3 II

To Fit

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1. Align the trolley lift with the powertrain and adjust its position in relation to the body. See «CENTERING TOOL, ENGINE AND SUBFRAME»(ref-275839-S09940813002007122900000) .
2. Lift up the power train until the inboard drive shaft universal joints are level with the wheel hubs and insert the drive shafts into the hubs. Make sure nothing gets caught or damaged.
3. Lift a little higher and position the lower swivel joints to the steering swivel members. If necessary, adjust the trolley lift screws to provide even contact with the body. Check that the guide pins are positioned correctly relative the reference holes in the body.
4. Position the bolts and screw them through the subframe into the body.
5. Raise the engine completely and tighten the subframe bolts. Tightening torque 75 Nm + 135° (55 lbf ft +135°)
6. Lower the trolley lift and move it out of the way.
7. Tighten the bolts on the lower swivel joints. Tightening torque 50 Nm (37 lbf ft) IMPORTANT: Ensure that the steering knuckle stub is visible on the top of the steering knuckle housing before the bolt is fitted.
8. Position the lower anti-roll bar links and tighten them while gripping the flats with a thin spanner. Tightening torque 64 Nm (47 lbf ft)
9. Position the outboard steering links and tighten them. Tightening torque 35 Nm (26 lbf ft)
10. Plug in the angle sensor connector (option).
11. Clean the pipe connections, fit a joint clamp on the front pipe and fit the front exhaust pipe to the catalytic converter, or fit the complete exhaust system. Use a new gasket and new nuts. Tightening torque 25 Nm (18 lbf ft)
12. If the pipe was cut, adjust the joint clamp so that the pipe ends are in the center of the joint clamp. Tighten the joint clamp nuts. Tightening torque 40 Nm (30 lbf ft).
13. Lower the car and fit the left-hand engine mounting. Tightening torque: 70 Nm + 45° (52 lbf ft + 45°)
14. Fit the right-hand engine pad. Tightening torque 70 Nm + 60° (52 lbf ft + 60°) Tightening torque, engine pad to body 40 Nm + 60° (30 lbf ft + 60°)
15. Remove the strap from the radiator member and the A/C compressor.
16. Remove the radiator member.
17. Raise the car, relieve «83 96 152 ENGINE CENTERING TOOL KIT»(ref-275839-S24833006412007122900000) and remove it from the subframe.
18. Secure the power steering pipe to the subframe with the clips.
19. Fit the A/C compressor and plug in the connector. Tightening torque 20 Nm (15 lbf ft).
20. Relieve the multigroove belt and mount it observing the rotation direction noted earlier. Use «83 96 095 BELT CIRCUIT RELIEVING TOOL B207»(ref-275839-S08227897002007122900000) .
21. Make sure the steering assembly is in straight-ahead position. Fit the steering shaft to the steering gear. Clean the threads and apply 74 96 268 Thread locking adhesive to the threads. Tightening torque 30 Nm (22 lbf ft)
22. Lower the car and remove the tape from the steering wheel. CV: Fit «CHASSIS REINFORCEMENT, FRONT SUBFRAME, CV, PETROL»(ref-275876-S05650643942007122900000) . WARNING: The work involved in removing the fuel pipe requires working with the vehicle's fuel system. The following points should therefore be heeded in conjunction with these measures: Have a class BE fire extinguisher on hand! Be aware of the risk of sparks, i.e. in connection with electric circuits, short-circuiting, etc. Absolutely No Smoking! Ensure good ventilation! If there is approved ventilation for evacuating fuel fumes then this must be used. Wear protective gloves! Prolonged exposure of the hands to fuel can cause irritation to the skin. Wear protective goggles.
23. Connect the quick-release coupling on the ventilation line and press the fuel lines and ventilation lines into the clips on the camshaft cover.
24. Remove the plugs and connect both fuel lines to the fuel rail while gripping the lower nut. Use new seals.
25. Connect the quick-release coupling to the clutch slave cylinder. Remove 30 07 739 Hose pinch-off pliers from the clutch hose. The connection must be mounted at the correct angle. Make sure the connection is secure.
26. Attach the gear cables to the gearbox.
27. Connect the coolant hose quick-release couplings. Change O-rings if necessary.
28. Fit the expansion tank on the body. Plug in the coolant level sensor connector.
29. Attach the ground cables and the clamp for the engine harness to the body.
30. Fit the retaining bolt for the engine harness connector in the main fuse box.
31. Fit the positive cable to the battery's positive terminal.
32. Fit the two retaining screws for the main fuse box and the main fuse box cover. Fit the windscreen washer filler pipe.
33. Fit the air filter housing and connect the intake hose. Fit the air filter and the air filter housing cover. IMPORTANT: To reduce the risk of hoses mounted on the delivery side of the turbocharger coming loose due to low friction at high air pressure, the hoses and connecting pieces must be cleaned thoroughly before fitting. Use a rag dampened with 93 160 907 Motip Dupli cleaning agent to wipe clean inside the ends of the hoses. Clean the connecting pieces as well. If hose clips are rusty or damaged, they must be replaced so the correct clamping force is maintained.
34. Plug in the mass air flow sensor connector. Remove the plug, fit the turbo inlet pipe and connect the hoses to the inlet pipe.
35. Plug in the connector for the A/C pressure sensor.
36. Fit the radiator. Cut off the cable ties.
37. Make sure the condenser and charge air cooler hooks are positioned correctly and fit the radiator retaining bolts.
38. Fit the upper radiator hose.
39. Fit the lower coolant hose.
40. Fit the fan cowling and press the A/C pipes into the retaining clips on the right structural member. Auto: Connect the oil pipes from the automatic transmission to the radiator.
41. Plug in both connectors on the left structural member.
42. Fit the upper radiator brackets to the body.
43. Fit the seal over the radiator core.
44. Plug in the reversing light switch connector.
45. Plug in the connector and attach the clip securing the cables on the fan cowling.
46. Fit the battery tray and the cable clip. Plug in the bonnet switch connector.
47. Fit the main fuse box in front of the battery tray. Plug in the connector under the control module.
48. Auto: Fit the cover with the TCM. Plug in the connector to the control module.
49. Connect the vacuum hose quick-release coupling to the vacuum pump.
50. Connect the ventilation hose to the radiator.
51. Fit «BATTERY (2006)»(ref-275860-S17428070512007122900000) or «BATTERY (2007)»(ref-279916-S20608419722008021800000) .
52. Fit the charge air hose to the throttle body and the upper charge air pipe bracket on the fan cowling.
53. Connect the hose to the bypass valve and the connector to the pressure/temperature sensor.
54. Fit the upper radiator crossmember
55. Connect the bonnet cable quick-release coupling and secure it to the body with new clips.
56. Fit the battery cover and the battery cooler pipe.
57. Raise the car and fit the lower seal between the charge air cooler and the radiator.
58. Fit the dryer filter bolts to the radiator.
59. Fit the hose between the charge air cooler and the charge air pipe and fit the cover on the right-hand side.
60. Fit the charge air pipe lower bracket on the fan cowling on the left-hand side.
61. Fit the charge air hose between the charge air pipe and the charge air cooler and fit the cover on the left-hand side.
62. Lower the car slightly and fit the bumper.
63. Connect the hose to the headlamp washers.
64. Fit the cover on the gearbox and the wing liners in both front wheel housings.
65. Fit the lower spoiler shield. Plug in and fit the connector.
66. Fit the drive shafts and tighten the hub center nuts. Tightening torque 230 Nm (170 lbf ft).
67. Fit the front «WHEELS»(ref-275839-S31569052022007122900000) .
68. Check oil level and top up as necessary. Fill with coolant to approx. 20 mm above the mark on the expansion tank. If a new engine is fitted, follow the instructions given in «BLEEDING THE COOLING SYSTEM WHEN WORKING WITH THE OIL COOLER»(ref-275852-S03845072162007122900000) .
69. Top up the washer fluid.
70. Bleed the clutch as described under «BLEEDING THE CLUTCH HYDRAULIC SYSTEM IN THE CAR»(ref-275841-S04447215482007122900000) .
71. «CHECKING THE TRANSMISSION FLUID LEVEL»(ref-275843-S10888626052007122900000) .
72. Remove the wing covers and restore car electrical functions, see «PROCEDURE AFTER RECONNECTING THE BATTERY»(ref-275839-S39476668922007122900000) .
73. Fit the upper engine cover.

Fit

1. Fit «CYLINDER HEAD»(ref-275839-S38563318952007122900000) .

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1. Apply wing covers and remove the battery cover and the negative battery cable.
2. Open the cap on the expansion tank.
3. Unplug the oxygen sensors and carefully take down the cables. WARNING: Take care as the engine can be very hot.
4. Remove the heat shield over the turbocharger.
5. Undo the turbocharger oil delivery pipe.
6. Remove the nuts for the catalytic converter connection with the turbocharger. IMPORTANT: When removing the nuts of the catalytic converter, it is important to hold the removal tool vertically against the flange. The stud and nut can easily be broken off if they are subjected to a skew loading. Use 82 92 484 Removal tool, door hinge.
7. Raise the car and remove the front right wheel and right wing liner.
8. Disconnect and bend aside one side of the lower spoiler shield. CV: Remove «CHASSIS REINFORCEMENT, FRONT SUBFRAME, CV, PETROL»(ref-275876-S05650643942007122900000).
9. Place a receptacle under the car, connect a hose to the radiator and drain the coolant.
10. Remove the lower turbocharger pressure pipe.
11. Undo the catalytic converter bracket from the cylinder block.
12. Use protective goggles. Place a receptacle under the car, connect a hose and open the cock on the coolant pump to drain the remaining coolant.
13. Close the cock. Tightening torque 20 Nm (15 lbf ft)
14. Undo the turbocharger coolant pipe.
15. Remove the stay between the exhaust manifold and the cylinder block.
16. Remove the oil return pipe from the turbocharger. IMPORTANT: If the flexible part of the return oil pipe is bent, the resulting restriction may become permanent and cause damage to the turbocharger.
17. Remove the stay between the intake manifold and the cylinder block.
18. Disconnect the starter motor positive cable.
19. Lower the car and remove the upper engine cover.
20. Remove the turbocharger delivery hose from the throttle body and the turbo delivery pipe
21. Detach the hoses and remove the turbo inlet pipe. Unplug the mass air flow sensor connector. Plug the turbo inlet.
22. Remove the air cleaner cover and the air cleaner. Detach the inlet hose and remove the air cleaner casing. WARNING: The work involved in removing the fuel pipe requires working with the vehicle's fuel system. The following points should therefore be heeded in conjunction with these measures: Have a class BE fire extinguisher on hand! Be aware of the risk of sparks, i.e. in connection with electric circuits, short-circuiting, etc. Absolutely No Smoking! Ensure good ventilation! If there is approved ventilation for evacuating fuel fumes then this must be used. Wear protective gloves! Prolonged exposure of the hands to fuel can cause irritation to the skin. Wear protective goggles.
23. Release any pressure in the fuel system by carefully pressing the service valve needle. Collect any fuel spill. Detach both fuel lines from the fuel rail while gripping the lower nut. Plug the fuel lines. Use 82 92 948 Plugs, A/C system assy.
24. Disconnect the quick-release coupling for the ventilation line and detach the fuel lines and ventilation lines from the clips on the camshaft cover. Bend up the ventilation hose from the intake manifold and place it on the camshaft cover.
25. Remove the cover over the ignition coils.
26. Unplug the ignition coil connectors. Unplug the connector to the turbocharger solenoid valve and undo the cable clips.
27. Unplug the A/C pressure sensor connector, the connector to the coolant temperature sensor, the engine control module, the bypass solenoid valve, the throttle body, the intake manifold pressure sensor, the atmospheric pressure sensor, the IDM module, the oil pressure sensor and the ground cable by the engine control module.
28. Detach the hose from the turbocharger wastegate and the solenoid valve.
29. Detach the cable duct and bracket from the camshaft cover. Move away the engine wiring harness.
30. Remove wiring harness nuts from oil filter housing and intake manifold and detach the wiring harness.
31. Remove the ignition coils.
32. Detach the crankcase ventilation hose from camshaft cover.
33. Undo ground cable from camshaft cover.
34. Remove the camshaft cover.
35. Zero the engine by turning the crankshaft clockwise until the mark on the crankshaft pulley is aligned with the mark on the timing cover, cyl. 1 cam lobes on intake and exhaust camshaft must be pointing in/up.
36. Detach the coolant hose from the pipe and the cylinder head.
37. Place a jack with a wood block under the oil sump and relieve the right-hand engine pad. Remove the right-hand engine mounting.
38. Detach the coolant hose from pipe on the cylinder head. Detach the vacuum hose from the brake servo.
39. Cars with secondary air injection pump: Remove the pump's pipe and upper retaining bolt from the intake manifold.
40. Undo the power steering pump.
41. Remove the dipstick tube bolt. Unplug the connector and detach it from the pipe.
42. Remove the chain tensioner. Use «83 96 129 OIL FILTER TOOL B207»(ref-275839-S00840118692007122900000)
43. Undo the camshaft sprockets. Restrain the respective camshaft using a spanner on the shaft flats.
44. Tie a cable tie around the exhaust camshaft sprocket and chain, remove the camshaft sprockets and lower the exhaust camshaft sprocket with chain.
45. Remove the plug from the cylinder head.
46. Remove the bolt for the chain guide on the intake side, move away the guide and refit the bolt.
47. Remove the cylinder head in the order (Scheme 98)

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1. Carefully clean the bolt holes in the cylinder block by blowing with compressed air.
2. Clean any gasket remains from the cylinder bore, cylinder head and cylinder block sealing surfaces. Check with a steel rule that the cylinder head and cylinder block are flat and the sealing surfaces are not damaged.
3. Check the marks on the pulley and timing cover to make sure the engine is zeroed.
4. Place a new gasket on the cylinder block. Raise the sprocket and pull the chain guides together in order to get the cylinder head in place.
5. Remove the exhaust camshaft and intake camshaft bearing cap no. 2. Fit «83 96 046 ADJUSTMENT TOOL, CAMSHAFT KIT»(ref-275839-S25707063912007122900000) or «83 96 079 ADJUSTMENT TOOL, CAMSHAFT (B207 200 HP»(ref-275839-S42279817962007122900000) ) onto the camshafts. IMPORTANT: When fitting the tools, use the screws accompanying the new tools EN-48366 and EN-48368. Tightening torque 10 Nm (7 lbf ft)
6. Fit the cylinder head according to the order (Scheme 101) Insert the bolts carefully. The threads in the cylinder block can be damaged if they are dropped rapidly. Tightening torque step 1: 30 Nm (22 lbf ft) Tightening torque step 2: 150° Tightening torque step 3: 15° Tightening torque, bolts for timing section, 35 Nm (26 lbf ft)
7. Remove the bolt for the chain guide. Move back the guide and fit the bolt. Tightening torque 10 Nm (7 lbf ft)
8. Fit the plug in the cylinder head. Tightening torque 25 Nm (18 lbf ft)
9. Fit the sprocket on the exhaust camshaft and intake camshaft without tightening. Check that the engine is zeroed.
10. Fit the chain guide "zeroed". The groove on the end of the chain tensioner must be vertical when fitting. See «TIMING CHAIN TENSIONER - FITTING»(ref-275839-S25032234342007122900000). Use «83 96 129 OIL FILTER TOOL B207, AND CHAIN TENSIONER CAMSHAFT DRIVE»(ref-275839-S00840118692007122900000) NOTE: Check that chain tensioner O-ring and gasket are intact. If damaged, the entire chain tensioner must be changed. Tightening torque 75 Nm (55 lbf ft)
11. Tighten the camshaft sprockets. Restrain the respective camshaft using a spanner on its flats. Remove the cable tie. Tightening torque 85 Nm + 30° (63 lbf ft +30°)
12. Remove the camshaft adjustment tool and fit the camshaft caps. Tightening torque 8 Nm (6 lbf ft)
13. Turn over the engine 2 revolutions and zero so that the belt pulley and the timing cover marks are aligned. Remove bearing caps no. 2 and no. 7 and fit «83 96 046 ADJUSTMENT TOOL, CAMSHAFT 175 HP»(ref-275839-S25707063912007122900000) or «83 96 079 ADJUSTMENT TOOL, CAMSHAFT (B207 200 HP»(ref-275839-S42279817962007122900000) ) again to check that the camshaft setting is correct. Remove the adjustment tools and fit the bearing caps. IMPORTANT: When fitting the tools, use the screws accompanying the new tools EN-48366 and EN-48368.
14. Fit the dipstick bolt. Plug in the connector and fit the connector to the tube.
15. Cars with secondary air injection pump: Fit the pump's upper retaining bolt. Fit the pipe between the pump and the valve.
16. Fit the power steering pump with new seal. Tightening torque 22 Nm (16 lbf ft)
17. Connect coolant hose to the pipe on cylinder head. Attach the vacuum hose to the brake servo.
18. Fit the right-hand engine pad. Tightening torque, bolts to body 40 Nm + 60° (30 lbf ft + 60°) Tightening torque, bolts to bracket 70 Nm + 60° (52 lbf ft + 60°)
19. Fit the coolant hose to the pipe on the cylinder head.
20. Fit the camshaft cover with new seal. Tightening torque 10 Nm (7 lbf ft)
21. Connect the ground cable to the camshaft cover.
22. Connect the crankcase ventilation hose to the camshaft cover.
23. Fit the ignition coils. Tightening torque 8 Nm (6 lbf ft)
24. Fit the wiring harness to the intake manifold and the oil filter housing.
25. Fit the cable duct and bracket to the camshaft cover.
26. Connect the hose to the turbocharger wastegate and the solenoid valve.
27. Plug in the A/C pressure sensor connector, the connector to the coolant temperature sensor, the engine control module, the bypass solenoid valve, the throttle body, the intake manifold pressure sensor, the atmospheric pressure sensor, the IDM module, the oil pressure sensor and the ground cable on the engine control module.
28. Plug in the ignition coil connectors. Make sure the cable is lying correctly and does not get pinched by the cover. Plug in the connector to the turbocharger solenoid valve and fasten the cable clips.
29. Fit the cover over the ignition coils.
30. Press the fuel lines and breather lines into the clips on the camshaft cover. Connect the quick release coupling for the breather line.
31. Connect both fuel lines to the fuel rail while restraining the lower nut. Use new seals. Tightening torque 10 Nm (7 lbf ft)
32. Fit the air cleaner casing and connect the intake hose. Fit the air cleaner. IMPORTANT: To reduce the risk of hoses mounted on the delivery side of the turbocharger coming loose due to low friction at high air pressure, the hoses and connecting pieces must be cleaned thoroughly before fitting. Use a rag dampened with 93 160 907 Motip Dupli cleaning agent to wipe clean inside the ends of the hoses. Clean the connecting pieces as well. If hose clips are rusty or damaged, they must be replaced so the correct clamping force is maintained.
33. Connect the air filter housing cover. Plug in the mass air flow sensor connector and fit the turbo inlet pipe. Attach the hoses to the turbo inlet pipe.
34. Fit the turbocharger delivery hose to the throttle body and the turbo delivery pipe.
35. Connect the starter motor positive cable.
36. Fit the stay between the intake manifold and the cylinder block. Tightening torque 22 Nm (16 lbf ft)
37. Fit the oil return pipe to the turbo. Use a new gasket and new O-ring. Tightening torque 15 Nm (11 lbf ft)
38. Fit the stay between the exhaust manifold and the cylinder block. Tightening torque 22 Nm (16 lbf ft)
39. Fit the turbo coolant pipe with new seals. Tightening torque 40 Nm (30 lbf ft).
40. Lower the car and fit the catalytic converter with new nuts so that it is butt against the turbo. Use 30 20 971 Screw-thread paste on the studs. Tightening torque 25 Nm (18 lbf ft)
41. Raise the car and tighten the catalytic converter bracket bolts. Tightening torque 25 Nm (18 lbf ft)
42. Fit the lower turbocharger pressure pipe.
43. Fit the lower spoiler shield. CV: Fit «CHASSIS REINFORCEMENT, FRONT SUBFRAME, CV, PETROL»(ref-275876-S05650643942007122900000).
44. Lower the car somewhat and fit the right wing liner and the front right wheel. See «WHEELS»(ref-275839-S31569052022007122900000).
45. Fit the turbo oil pressure pipe. Use new seals and grip the pipe to prevent it twisting. Tightening torque 22 Nm (16 lbf ft)
46. Plug in the oxygen sensor connectors.
47. Fit the heat shield over the turbocharger.
48. Connect battery negative cable and battery cover.
49. Check the oil level and top up as necessary.
50. Fill with coolant to approx. 20 mm above the mark on the expansion tank.
51. Remove the wing covers and restore car electrical functions, see «PROCEDURES AFTER DISCONNECTING THE BATTERY»(ref-275839-S39476668922007122900000).
52. Fit the upper engine cover.

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1. Remove the upper engine cover.
2. Undo the oil filter cover (A) using «83 96 129 OIL FILTER TOOL B207»(ref-275839-S00840118692007122900000)
3. Raise the car and place a receptacle underneath.
4. Remove the drain plug (A) and drain the engine oil.
5. Fit the oil plug with a new O-ring (A). Tightening torque 25 Nm (18 lbf ft)
6. Lower the car, remove the cover and the filter element as well as the O-ring from the cover. Collect any spilled oil with a rag.
7. Fit a new filter element (A) and O-ring to the cover (B), lubricate the O-ring with engine oil.
8. Fit the filter cover. Tightening torque 25 Nm (18 lbf ft)
9. Fill with engine oil, see «RECOMMENDED OIL QUALITY»(ref-275836-S39457799062007122900000) .
10. Connect an exhaust hose, start the engine and let it run for 30 seconds before turning it off.
11. Check the oil level after 3-5 minutes. Top up with oil as necessary.
12. Fit the upper engine cover.

Scheme 131

1. Remove «TIMING CHAIN AND CAMSHAFT SPROCKET»(ref-275839-S00114508472007122900000) .
2. Remove the chain tensioner and chain guide rails.
3. Remove the chain.

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1. Fit the chain. Start fitting on the water pump pinion. Continue as follows: The silver-colored link must be fitted to the exhaust side balancer shaft sprocket. The copper-colored link must be fitted to the intake side balancer shaft sprocket. The silver-colored link must be fitted to crankshaft sprocket.
2. Fit the chain guide rails. Use 74 96 268 Thread locking adhesive. Tightening torque 10 Nm (7 lbf ft)
3. Fit the chain tensioner. Load the tensioner by pressing in the plunger and turning to the right. Fit the chain tensioner and secure with tool «83 96 392 LOCK PIN»(ref-275839-S15988022542007122900000) .
4. Fit the chain tensioner screws. Use 74 96 268 Thread locking adhesive. Tightening torque 10 Nm (7 lbf ft)
5. Remove the tool from the tensioner. Press the tensioner guide rail to check that backward movement of the plunger is prevented.
6. Fit «TIMING CHAIN AND CAMSHAFT SPROCKET»(ref-275839-S00114508472007122900000) .

Scheme 135

1. Remove «TIMING CHAIN AND CAMSHAFT SPROCKET»(ref-275839-S00114508472007122900000) .
2. Remove the chain's guide rails. Remove the chain tensioner (A) Remove the chain's guide rails (B)

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1. Fit the chain: Start to fit the water pump pinion. The silver-colored link must be fitted to the exhaust side balancer shaft sprocket (B). The copper-colored link must be fitted to the intake side balancer shaft sprocket (C) The silver-colored link must be fitted to crankshaft sprocket (D).
2. Fit the chain's guide rails. Use Thread locking adhesive Loctite 242. Tightening torque 10 Nm (7 lbf ft)
3. Fit the chain tensioner. Load the chain tensioner by pressing in the plunger and turning to the right (A). Then secure with tool «83 96 392 LOCK PIN»(ref-275839-S15988022542007122900000) .
4. Fit the chain tensioner screws (A). Use 74 96 268 Thread locking adhesive. Tightening torque 10 Nm (7 lbf ft)
5. Remove the tool from the tensioner. Press the tensioner guide rail to check that backward movement of the plunger is prevented.
6. Fit «TIMING CHAIN AND CAMSHAFT SPROCKET»(ref-275839-S00114508472007122900000) .

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Scheme 140

1. Raise the car, twist the wheel out and release the front part of the right wing liner.
2. Relieve the belt tensioner using «83 96 095 BELT CIRCUIT RELIEVING TOOL B207»(ref-275839-S08227897002007122900000) and remove the belt. Mark the direction of rotation of the belt.
3. Remove the belt tensioner.
4. Remove the breaker wheel.

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1. Fit the breaker wheel to the belt tensioner. Tightening torque 25 Nm (18 lbf ft).
2. Fit the belt tensioner. Tightening torque 50 Nm (37 lbf ft).
3. Relieve the belt tensioner with «83 96 095 BELT CIRCUIT RELIEVING TOOL B207»(ref-275839-S08227897002007122900000) and fit the belt in the marked direction of rotation.
4. Mount the front part of the wing liner and lower the car.

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1. Man: Put the gear lever in neutral. Auto: Put the selector lever in position P. Remove the key from the ignition switch.
2. Remove relay no. 8 in the «ENGINE BAY ELECTRICAL CENTER 342 (UEC) (2006)»(ref-275860-S30669348352007122900000) or «ENGINE BAY ELECTRICAL CENTER 342 (UEC) (2007)»(ref-279916-S18911752452008021800000) .
3. Connect «83 93 886 DIAGNOSTICS CABLE, LH SYSTEM»(ref-275839-S12283331932007122900000) to relay holder sleeves 87 and 30. Make sure that the switch is in the OFF position.
4. Remove the cover over the ignition coils, undo the ignition coils and move them aside.
5. Remove the spark plugs.
6. Fit the Motometer compression tester for petrol engines to cylinder 1 with a new card.
7. Run the starter motor using the test lead switch until the needle stops rising.
8. Repeat the measurement procedure on the other cylinders. For minimum compression pressure, see «GENERAL DATA»(ref-275839-S08633025812007122900000) .

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1. Fit the spark plugs. Tightening torque 20 Nm (15 lbf ft).
2. Fit the ignition coils. Tightening torque 8 Nm (6 lbf ft).
3. Fit the cover over the ignition coils.
4. Remove the test cable and put back relay no. 8.

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1. Remove «CAMSHAFT COVER WITH GASKET»(ref-275839-S30583539642007122900000)
2. Remove the right-hand «FRONT WING LINER»(ref-275838-S09185847162007122900000) .
3. Lower the car and zero the engine by turning the crankshaft in the direction of rotation of the engine until the marking on the crankshaft pulley is aligned with the marking on the timing cover. The cam lobes on cylinder 1 intake and exhaust camshafts should be pointing up/in. (A)
4. Remove the chain tensioner (A). Use «83 96 129 OIL FILTER TOOL, B207, AND CAMSHAFT DRIVE CHAIN TENSIONER»(ref-275839-S00840118692007122900000)
5. Remove the lock ring (C) from the chain tensioner and remove the piston.
6. Remove the upper timing chain guide rail (C).
7. Remove the camshaft pinions. Grip the camshaft flats with a spanner when loosening the bolts.

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1. Clean the camshaft and pinion contact surfaces (A) from oil and grease.
2. Align the chain on the pinions, fit the pinions on the camshaft and fit the bolts. Turn the camshaft drive tensioner clockwise with a screwdriver until it engages in the tensioned position (A).
3. Place the plunger in the chain tensioner sleeve. Fit the circlip (A) and check that it is fitted correctly in the groove. NOTE: Check that the O-ring and gasket are intact. If damaged, replace the chain tensioner assembly.
4. Fit the chain tensioner (A). Tightening torque 75 Nm (55 lbf ft)
5. Release/activate the chain tensioner by carefully pressing on the timing chain or chain guide (as shown in the illustration). Use a screwdriver (A). Check that the tensioner has released.
6. Remove the exhaust camshaft and intake camshaft bearing caps no. 2 and no. 7. Position «83 96 046 ADJUSTMENT TOOL, CAMSHAFT (B207 150-175 HP)»(ref-275839-S25707063912007122900000) and «83 96 079 ADJUSTMENT TOOL, CAMSHAFT (B207 210 HP)»(ref-275839-S42279817962007122900000) by manually pressing the tools down onto the camshafts without tightening the bolts. Turn the camshaft until the tool aligns with the spanner on the camshaft flats. Tighten the adjustment tools' bolts (A). Tightening torque 10 Nm (7 lbf ft)
7. Check that the markings on the crankshaft pulley and the timing cover are aligned. Tighten the camshaft gears a first time. Use a wrench to grip the camshaft flats (A). Tightening torque 30 Nm (22 lbf ft)
8. Remove the adjustment tools and fit the bearing caps (B). Tightening torque 8 Nm (6 lbf ft)
9. Continue to tighten the camshaft gears to the final torque. Use a wrench to grip the camshaft flats (A). Tightening torque 85 Nm + 30° (63 lbf ft +30°)
10. Turn the crankshaft 2 rotations in the engine's direction of rotation until the markings on the crankshaft pulley and the timing cover are aligned. Remove the bearing caps and refit «83 96 046 ADJUSTMENT TOOL, CAMSHAFT (B207 150-175 HP)»(ref-275839-S25707063912007122900000) and «83 96 079 ADJUSTMENT TOOL, CAMSHAFT (B207 210 HP)»(ref-275839-S42279817962007122900000) to check that the camshaft setting is correct. Remove the adjustment tools and fit the bearing caps. Tightening torque 8 Nm (6 lbf ft)
11. Fit the upper timing chain guide rail (C).
12. Fit «CAMSHAFT COVER WITH GASKET»(ref-275839-S30583539642007122900000)
13. Fit the right-hand «FRONT WING LINER»(ref-275838-S09185847162007122900000)
14. Fit the right-hand front wheel. See «WHEELS»(ref-275839-S31569052022007122900000) .
15. Lower the car completely. Check the engine's oil level.
16. Top up as necessary.

Scheme 161

Scheme 162

Scheme 163

Scheme 164

Scheme 165

1. Raise the car and remove the front right wheel.
2. Remove the right wing liner. CV: Remove «CHASSIS REINFORCEMENT, FRONT SUBFRAME, CV, PETROL»(ref-275876-S05650643942007122900000) .
3. Relieve the belt tensioner using «83 96 095 BELT CIRCUIT RELIEVING TOOL B207»(ref-275839-S08227897002007122900000) and remove the belt. Mark the direction of rotation of the belt.
4. Remove the belt tensioner.
5. Lower the car and remove the upper engine cover.
6. Unplug the mass air flow sensor connector and detach the inlet hose from the air cleaner casing cover. Remove the cover and the air filter.
7. Detach the inlet hose and remove the air cleaner casing. Unplug the connector for the A/C pressure sensor.
8. Remove the turbocharger heat shield.
9. Fit «83 96 178 LIFTING EYE KIT B207»(ref-275840-S24398113142007122900000) .
10. Fit «83 94 850 LIFTING BEAM»(ref-275839-S15977290372007122900000) and «83 95 287 HOLDER»(ref-275840-S08151924372007122900000) . Take the weight off the engine and remove the bolts in the engine bracket.
11. Lower the engine about 3 cm using the lifting beam.
12. Raise the car and remove the crankshaft pulley using «83 95 360 HOLDING TOOL, CRANKSHAFT PULLEY (SHAFT ONLY)»(ref-275839-S33056487122007122900000) and «83 96 210 HOLDING TOOL, CRANKSHAFT PULLEY, B207»(ref-275839-S40501209642007122900000)
13. Place a receptacle under the car to collect the oil and carefully remove the timing cover.
14. Cut away the timing cover gasket around the engine mounting and remove the gasket.
15. Remove the crankshaft seal.

Scheme 166

Scheme 167

Scheme 168

Scheme 169

Scheme 170

Scheme 171

Scheme 172

1. Clean all the sealing surfaces.
2. Cut off the part of the gasket that is around the engine mounting and position the new timing cover gasket.
3. Fit the timing cover. Tightening torque 20 Nm (15 lbf ft).
4. Position the «83 96 202 FITTING TOOLS, FRONT CRANKSHAFT SEAL B207»(ref-275839-S18098714552007122900000) protective collar on the crankshaft. Lubricate the new sealing ring with non-acidic Vaseline and position it on the fitting tool.
5. Position the fitting tool on the crankshaft. Screw in the sealing ring using the crankshaft pulley bolt so that it is flush with the timing cover. Remove the tool.
6. Fit the crankshaft pulley with a new bolt. Use «83 95 360 HOLDING TOOL, CRANKSHAFT PULLEY (SHAFT ONLY)»(ref-275839-S33056487122007122900000) and «83 96 210 HOLDING TOOL, CRANKSHAFT PULLEY, B207»(ref-275839-S40501209642007122900000) . Tightening torque 100 Nm + 75° (74 lbf ft + 75°)
7. Lower the car and raise the engine with the lifting beam until it rests against the engine mounting.
8. Fit the bolts to the engine bracket. Remove «83 94 850 LIFTING BEAM»(ref-275839-S15977290372007122900000) with holder. Tightening torque 70 Nm + 60° (52 lbf ft + 60°)
9. Remove «83 96 178 LIFTING EYE KIT B207»(ref-275840-S24398113142007122900000) .
10. Fit the turbocharger heat shield.
11. Fit the air cleaner casing and connect the intake hose. Plug in the A/C pressure sensor connector.
12. Fit the filter element and the air cleaner casing cover. Connect the inlet hose and the mass air flow sensor connector.
13. Fit the upper engine cover.
14. Raise the car and fit the belt tensioner. Tightening torque 50 Nm (37 lbf ft).
15. Relieve the belt tensioner with «83 96 095 BELT CIRCUIT RELIEVING TOOL B207»(ref-275839-S08227897002007122900000) and fit the belt in the marked direction of rotation. Make sure the belt is located correctly on all the pulleys. CV: Fit «CHASSIS REINFORCEMENT, FRONT SUBFRAME, CV, PETROL»(ref-275876-S05650643942007122900000)
16. Lower the car slightly and fit the right wing liner.
17. Fit the front right wheel. See «WHEELS»(ref-275839-S31569052022007122900000) .
18. Lower the car to the floor.
19. Check the engine oil level. Top up as necessary.

Scheme 173

Scheme 174

Scheme 175

Scheme 176

Scheme 177

Scheme 178

Scheme 179

Scheme 180

Scheme 181

Scheme 182

Scheme 183

Scheme 184

Scheme 185

Scheme 186

Scheme 187

Scheme 188

1. Remove the upper engine cover.
2. Detach the mass air flow sensor connector and the intake hose from the air filter housing cover. Remove the cover and the air filter.
3. Detach the intake hose and remove the air filter housing. Detach the connector for the A/C pressure sensor.
4. Undo the fuel pipes from the snap fasteners and remove the bolts for the bracket from the camshaft cover.
5. Remove cover over ignition coils.
6. Unplug ignition coil connectors. Unplug connector to turbocharger solenoid valve and undo cable clips.
7. Remove the bolts, pick up and move aside each ignition coil. Start with ignition coil for cyl. 1.
8. Detach crankcase ventilation hose from camshaft cover.
9. Undo and carefully move away the cable duct from the cylinder head and camshaft cover.
10. Remove the turbocharger heat shield.
11. Undo ground cable from camshaft cover.
12. Remove the camshaft cover.
13. Raise the car and remove the front right wheel.
14. Remove the right wing liner. CV: Remove «CHASSIS REINFORCEMENT, FRONT SUBFRAME, CV, PETROL»(ref-275876-S05650643942007122900000) .
15. Relieve the belt tensioner with «83 96 095 RELIEVING TOOL, BELT CIRCUIT B207»(ref-275839-S08227897002007122900000) and remove the belt. Mark the direction of rotation on the belt.
16. Remove the belt tensioner.
17. Lower the car and zero the engine by turning the crankshaft in the direction of engine rotation until the mark on the crankshaft pulley agrees with the mark on the timing cover. The cams on cylinder 1 intake and exhaust camshaft must be pointing in/up.
18. Remove the chain tensioner. Use «83 96 129 OIL FILTER TOOL, B207, AND CAMSHAFT DRIVE CHAIN TENSIONER»(ref-275839-S00840118692007122900000) .
19. Remove the lock ring from the chain tensioner and remove the piston.
20. Fit «83 96 178 LIFTING EYES, KIT, B207»(ref-275840-S24398113142007122900000) .
21. Fit «83 94 850 LIFTING BEAM»(ref-275839-S15977290372007122900000) and «83 95 287 HOLDER»(ref-275840-S08151924372007122900000) . Relieve the engine and remove the engine bracket.
22. Lower the engine about 3 cm using the lifting beam.
23. Raise the car and remove the crankshaft pulley with «83 95 360 HOLDING TOOL, CRANKSHAFT PULLEY (SHAFT ONLY)»(ref-275839-S33056487122007122900000) and «83 96 210 HOLDING TOOL, CRANKSHAFT PULLEY, B207»(ref-275839-S40501209642007122900000) .
24. Place a receptacle under the car to collect any oil and carefully remove the timing cover.
25. Cut off the part of the timing cover gasket that goes round the engine mounting and remove the gasket.
26. Remove the crankshaft seal. Lower the car.
27. Remove the plug from the cylinder head.
28. Remove the upper bolt from the chain guide on the inlet side.
29. Remove the upper timing chain guide rail.
30. Remove the lower chain guide bolt. Pull down the chain guide. Detach the lower section of the chain.
31. Remove the camshaft sprockets. Use a spanner to grip the camshaft flats when the bolts are loosened. Lift up the chain.
32. Remove the tensioner guide by lifting it up. Inspect the condition of the guide. Replace if necessary.

Scheme 189

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Scheme 192

Scheme 193

Scheme 194

Scheme 195

Scheme 196

Scheme 197

Scheme 198

Scheme 199

Scheme 200

Scheme 201

Scheme 202

Scheme 203

Scheme 204

Scheme 205

Scheme 206

Scheme 207

Scheme 208

1. Clean all sealing surfaces.
2. Clean the camshaft and sprocket contact surfaces from oil and grease.
3. Fit the tensioner guide.
4. Lay the chain on the intake sprocket and lower the chain. Fit the sprocket on the camshaft and insert the bolt.
5. Raise the car.
6. Fit the chain on the crankshaft sprocket and fit the chain guide. Fit the lower bolt. Tightening torque 10 Nm (7 lbf ft)
7. Lower the car.
8. Fit the exhaust sprocket and enter the bolt.
9. Fit the upper bolt. Fit the plug on the cylinder head.
10. Turn the camshaft drive tensioner clockwise with a screwdriver until it engages in the tensioned position.
11. Place the plunger in the chain tensioner sleeve. Fit the circlip and check that it is fitted correctly in the groove. NOTE: Check that the O-ring and gasket are intact. If damaged, replace the chain tensioner assembly.
12. Fit the chain tensioner. Tightening torque 75 Nm (55 lbf ft)
13. Release/activate the chain tensioner by carefully pressing on the transmission chain or chain control (as shown). Use a screwdriver. Check that the tensioner releases.
14. Remove the exhaust camshaft and intake camshaft bearing caps no. 2 and no. 7. Position «83 96 046 ADJUSTMENT TOOL, CAMSHAFT (B207 150-175 HP)»(ref-275839-S25707063912007122900000) and «83 96 079 ADJUSTMENT TOOL, CAMSHAFT (B207 200 HP)»(ref-275839-S42279817962007122900000) by pressing down the tool by hand onto the camshafts without tightening the bolts. Rotate the camshaft with a wrench on the camshaft flats until the tool fits. Tighten the adjustment tools' bolts. IMPORTANT: When fitting the tools, use the screws accompanying the new tools EN-48366 and EN-48368. Tightening torque 10 Nm (7 lbf ft)
15. Cut off the part of the gasket that is round the engine mounting and position the new timing cover gasket.
16. Fit the timing cover. Tightening torque 20 Nm (15 lbf ft).
17. Position the «83 96 202 FITTING TOOL, FRONT CRANKSHAFT SEAL B207»(ref-275839-S18098714552007122900000) protective collar on the crankshaft. Lubricate the new sealing ring with acid-free Vaseline and position it on the fitting tool.
18. Position the fitting tool on the crankshaft. Tighten the sealing ring using the crankshaft pulley bolt until it is flush with the timing cover. Remove the tool.
19. Fit the crankshaft pulley with a new bolt. Use «83 95 360 HOLDING TOOL, CRANKSHAFT PULLEY (SHAFT ONLY)»(ref-275839-S33056487122007122900000) and «83 96 210 HOLDING TOOL, CRANKSHAFT PULLEY, B207»(ref-275839-S40501209642007122900000) . Tightening torque 100 Nm + 75° (74 lbf ft + 75°)
20. Check that the markings on the crankshaft pulley and the timing cover are aligned. Tighten the camshaft gears a first time. Use a spanner to grip the camshaft flats. Tightening torque 30 Nm (22 lbf ft)
21. Remove the adjustment tools and fit the bearing caps. Tightening torque 8 Nm (6 lbf ft)
22. Continue to tighten the camshaft gears to the final torque. Use a spanner to grip the camshaft flats. Tightening torque 85 Nm + 30° (63 lbf ft +30°)
23. Turn the crankshaft 2 rotations in the engine direction of rotation until the markings on the crankshaft pulley and the timing cover are aligned. Remove the bearing caps and refit «83 96 046 ADJUSTMENT TOOL, CAMSHAFT (B207 150-175 HP)»(ref-275839-S25707063912007122900000) and «83 96 079 ADJUSTMENT TOOL, CAMSHAFT (B207 200 HP)»(ref-275839-S42279817962007122900000) to check that the camshaft setting is correct. Remove the adjustment tools and fit the bearing caps. IMPORTANT: When fitting the tools, use the screws accompanying the new tools EN-48366 and EN-48368. Tightening torque 8 Nm (6 lbf ft)
24. Fit the upper timing chain guide rail.
25. Lower the car and lift the engine with the lifting beam. Fit the engine bracket.
26. Fit the bolts to the engine bracket. Tightening torque 70 Nm + 60° (52 lbf ft + 60°)
27. Remove «83 94 850 LIFTING BEAM»(ref-275839-S15977290372007122900000) with holder. Remove 83 96 178 Lifting eye kit, B207.
28. Fit the camshaft cover with new seal. Tightening torque 10 Nm (7 lbf ft)
29. Connect the ground cable to the camshaft cover.
30. Connect the crankcase ventilation hose to the camshaft cover.
31. Fit the cable duct and bracket to the camshaft cover.
32. Fit the ignition coils. Tightening torque 8 Nm (6 lbf ft)
33. Plug in the ignition coil connectors. Make sure the cable is lying correctly and does not get pinched by the cover. Plug connector to turbocharger solenoid valve and cable clips.
34. Fit cover over ignition coils.
35. Press the fuel lines and breather lines into the clips on the camshaft cover. Connect the quick release coupling for the breather line.
36. Connect both fuel lines to the fuel rail while gripping the lower nut. Use new seals. Tightening torque 10 Nm (7 lbf ft)
37. Fit the turbocharger heat shield.
38. Fit the air filter housing and connect the intake hose. Plug in the connector for the A/C pressure sensor.
39. Fit the air cleaner and air cleaner cover. Connect the intake hose and the mass air flow sensor connector.
40. Fit the upper engine cover.
41. Raise the car and fit the belt tensioner. Tightening torque 50 Nm (37 lbf ft).
42. Relieve the belt tensioner with «83 96 095 RELIEVING TOOL, BELT CIRCUIT B207»(ref-275839-S08227897002007122900000) and fit the belt in the marked direction of rotation. Check that the belt is positioned correctly over all the pulleys. CV: Fit «CHASSIS REINFORCEMENT, FRONT SUBFRAME, CV, PETROL»(ref-275876-S05650643942007122900000) .
43. Lower the car somewhat and fit the right wing liner.
44. Fit the front right wheel. See «WHEELS»(ref-275839-S31569052022007122900000) .
45. Lower the car completely.
46. Check engine oil level. Top up as necessary.

Scheme 209

1. Raise the car and undo the front part of the right wing liner.
2. Relieve the belt tensioner using «83 96 095 BELT CIRCUIT RELIEVING TOOL B207»(ref-275839-S08227897002007122900000) and remove the belt.

Scheme 210

1. Relieve the belt tensioner using «83 96 095 BELT CIRCUIT RELIEVING TOOL B207»(ref-275839-S08227897002007122900000) and refit the drive belt.
2. Check the belt position on all pulleys.
3. Fit the screws and nut for the right wing liner.
4. Lower the car, start the engine and check the belt function.

Check the engine oil pressure

Scheme 211

1. Remove the turbocharger heat shield.
2. Remove the banjo nipple in the turbocharger oil delivery pipe, collect any oil spill.
3. Fit 83 93 852 Pressure measuring equipment, fuel and oil with new sealing washers. Make sure the hose is not resting on sharp or hot components.
4. Start the engine and read off the pressure. See «OIL PRESSURE»(ref-275839-S25975356752007122900000) under Lubricating system. Turn off the engine.
5. Make sure the pressure gauge is showing 0 bar before detaching it from the adapter. Remove the pressure gauge and the adapter. Wipe away any spilled oil.
6. Fit the banjo nipple with new sealing washers. Grip the pipe so it does not turn. Tightening torque 22 Nm (16 lbf ft).
7. Fit the turbocharger heat shield.

Scheme 212

Scheme 213

Scheme 214

Scheme 215

Scheme 216

Scheme 217

Scheme 218

Scheme 219

Scheme 220

1. Remove the upper engine cover.
2. Release the mass air flow sensor connector. Detach the turbocharger inlet hose from the filter casing. Remove the air filter.
3. Detach the fuel pipe from the snap fastening and remove the fastening bolts from the camshaft cover.
4. Remove the cover over the ignition coils.
5. Remove the bolts, lift up each ignition coil and move aside. Start with the ignition coil for cylinder 1.
6. Detach the crankcase ventilation hose from the camshaft cover.
7. Detach and carefully guide the cable duct out of the cylinder head and camshaft cover.
8. Detach the ground lead from the camshaft cover.
9. Remove the heat shield over the turbocharger.
10. Remove the camshaft cover.
11. Raise the car and remove the right-hand wheel.
12. Remove the right wing liner.
13. Relieve the belt tensioner using «83 96 095 BELT CIRCUIT RELIEVING TOOL B207»(ref-275839-S08227897002007122900000) E/L. Mark the direction of rotation of the belt.
14. Lower the car and zero the engine by turning the crankshaft clockwise until the marking on the crankshaft pulley is aligned with the marking on the timing cover. The cyl. 1 cams on the intake and exhaust camshafts should be pointing up/in.
15. Remove exhaust camshaft and intake camshaft no. 2 and no. 7 bearing caps. Fit «83 96 046 CAMSHAFT ADJUSTMENT TOOL KIT 175 HP»(ref-275839-S25707063912007122900000) or «83 96 079 CAMSHAFT ADJUSTMENT TOOL (B207 200 HP)»(ref-275839-S42279817962007122900000) by pressing manually down on the tool on the camshafts without tightening the bolts.. IMPORTANT: When fitting the tools, use the screws accompanying the new tools EN-48366 and EN-48368.
16. If the adjustment tool does not fit onto the cams, loosen some of the camshaft pulley bolts, grip the camshaft flats with a wrench. Tighten the adjustment tool bolts. Tightening torque 10 Nm (7 lbf ft).
17. Check that the markings on the camshaft pulley and timing cover align. Tighten the camshaft pulley once, grip the camshaft flats with a wrench. Tightening torque 30 Nm (22 lbf ft)
18. Remove the adjustment tools and fit the bearing caps. Tightening torque 8 Nm (6 lbf ft).
19. Turn the camshaft pulley further to the final point. Grip the camshaft flats with a wrench. Tightening torque 85 Nm + 30° (63 lbf ft +30°)
20. Turn the crankshaft twice in the engine direction of rotation until the markings on the pulley and the timing cover are aligned. Remove bearing caps and refit «83 96 046 CAMSHAFT ADJUSTMENT TOOL KIT 175 HP»(ref-275839-S25707063912007122900000) or «3 96 079 CAMSHAFT ADJUSTMENT TOOL (B207 200 HP)»(ref-275839-S42279817962007122900000) to check that the camshaft setting is correct. Remove the adjustment tools and fit the bearing caps. IMPORTANT: When fitting the tools, use the screws accompanying the new tools EN-48366 and EN-48368. Tightening torque 8 Nm (6 lbf ft).

Scheme 221

Scheme 222

Scheme 223

Scheme 224

Scheme 225

Scheme 226

Scheme 227

1. Raise the car, relieve the belt tensioner and refit the belt in the direction of rotation marked.
2. Refit the right wing liner.
3. Fit «WHEEL»(ref-275842-S20194743172007122900000)
4. Lower the car and fit the camshaft cover with new gasket. Check that the gaskets remain correctly seated during fitting. Tightening torque 10 Nm (8 lbf ft)
5. Fit the heat shield over the turbocharger. Ensure that the clip under the heat shield is fastened to the holder.
6. Connect the ground cable to the camshaft cover.
7. Fit the cable duct on the camshaft cover.
8. Connect the crankcase ventilation hose to the camshaft cover.
9. Refit ignition coils. Start with the ignition coil for cyl. 4. Tightening torque 8 Nm (6 lbf ft).
10. Fit the cover over the ignition coils.
11. Fit the bolts for the camshaft cover mounting and fit the fuel pipe in the snap fastening.
12. Refit the air filter.
13. Fit the filter housing cover. Connect the mass air flow sensor connector. Connect the turbo inlet hose to the air filter.
14. Fit the upper engine cover.

Scheme 228

Scheme 229

Scheme 230

Scheme 231

1. Remove the upper engine cover.
2. Release the mass air flow sensor connector. Detach the inlet hose and remove the filter casing. Remove the air filter.
3. Detach the fuel pipe from the snap fastening and remove the fastening bolts from the camshaft cover.
4. Remove the cover over the ignition coils.
5. Remove the bolts, lift up each ignition coil and move aside. Start with the ignition coil for cylinder 1.
6. Detach the crankcase ventilation hose from the camshaft cover.
7. Detach and carefully guide the cable duct out of the cylinder head and camshaft cover.
8. Detach the ground lead from the camshaft cover.
9. Remove the heat shield over the turbocharger.
10. Remove the camshaft cover.
11. Remove the camshaft cover gasket and seals around the spark plug holes.

Scheme 232

Scheme 233

Scheme 234

Scheme 235

1. Fit the camshaft cover with new gaskets for the bolts. Check that the gaskets remain in place during fitting. Tightening torque 10 Nm (8 lbf ft)
2. Fit the heat shield over the turbocharger. Ensure that the clip under the heat shield is fastened to the holder.
3. Connect the ground cable to the camshaft cover.
4. Fit the cable duct on the camshaft cover.
5. Connect the crankcase ventilation hose to the camshaft cover.
6. Refit ignition coils. Start with the ignition coil for cyl. 4. Tightening torque 8 Nm (6 lbf ft).
7. Fit the cover over the ignition coils.
8. Fit the bolts for the camshaft cover mounting and fit the fuel pipe in the snap fastening.
9. Refit the air filter and filter housing cover. Connect the mass air flow sensor connector.
10. Connect the inlet hose.
11. Fit the upper engine cover.

Scheme 236

Scheme 237

Scheme 238

1. Detach the turbocharger inlet hose from the filter casing. Remove the cover and filter from the filter casing.
2. Detach the hoses from the inlet hose. Remove the inlet hose.
3. Remove the chain tensioner. Use «83 96 129 OIL FILTER TOOL, B207, AND CAMSHAFT DRIVE CHAIN TENSIONER»(ref-275839-S00840118692007122900000) .
4. Remove the lock ring from the chain tensioner and remove the piston.

Scheme 239

Scheme 240

Scheme 241

Scheme 242

1. Turn the camshaft drive tensioner clockwise with a screwdriver until it engages in the tensioned position.
2. Place the plunger in the chain tensioner sleeve. Fit the circlip and check that it is fitted correctly in the groove. NOTE: Check that the O-ring and gasket are intact. If damaged, replace the chain tensioner assembly.
3. Fit the chain tensioner. Tightening torque 75 Nm (55 lbf ft).
4. Remove the camshaft cover.
5. Release/activate the chain tensioner by carefully pressing on the transmission chain or chain control. Use a screwdriver. Check that the tensioner releases.
6. Fit camshaft cover.

Scheme 243

Scheme 244

Scheme 245

Scheme 246

1. Raise the car, remove the right front wheel.
2. Remove the right wing liner.
3. Mark the belt direction of rotation. Relieve the belt tensioner using «83 96 095 BELT CIRCUIT RELIEVING TOOL B207»(ref-275839-S08227897002007122900000) and remove the poly-V-belt.
4. Remove the crankshaft pulley using «83 95 360 HOLDING TOOL, CRANKSHAFT PULLEY (SHAFT ONLY)»(ref-275839-S33056487122007122900000) and «83 96 210 HOLDING TOOL, CRANKSHAFT PULLEY, B207»(ref-275839-S40501209642007122900000) . Fold up the plate and carefully hold the engine down slightly with a bracket to gain access to the bolt.
5. Remove the gasket using a 87 91 360 Extractor

Scheme 247

Scheme 248

Scheme 249

1. Clean the sealing surfaces.
2. Position the «83 96 202 FITTING TOOLS, FRONT CRANKSHAFT SEAL B207»(ref-275839-S18098714552007122900000) protective collar on the crankshaft. Lubricate the new sealing ring with non-acidic Vaseline and position it on the fitting tool.
3. Position the fitting tool on the crankshaft. Screw in the sealing ring using the crankshaft pulley bolt so that it is flush with the timing cover. Remove the tool.
4. Fit the crankshaft pulley with a new bolt. Use «83 95 360 HOLDING TOOL, CRANKSHAFT PULLEY (SHAFT ONLY)»(ref-275839-S33056487122007122900000) and «83 96 210 HOLDING TOOL, CRANKSHAFT PULLEY, B207»(ref-275839-S40501209642007122900000) . Hold the engine down slightly with a bracket to gain access to the bolt. Bend the plate back and spray 30 15 948 Cavity fluid to prevent rust damage. Tightening torque 100 Nm + 75° (74 lbf ft + 75°)
5. Relieve the belt tensioner using «83 96 095 BELT CIRCUIT RELIEVING TOOL B207»(ref-275839-S08227897002007122900000) and refit the poly-V-belt in the direction of rotation marked. Check the belt position on all pulleys.
6. Fit the wing liner.
7. Fit Wheel.
8. Lower the car, check the engine oil level and top up if necessary.

Scheme 250

1. Remove the gearbox, see Complete gearbox man. B207 or Complete automatic transmission.
2. Remove the pressure plate and clutch drive plate, see «CLUTCH ASSEMBLY»(ref-275841-S00742841292007122900000) .
3. Remove the driver plate or «FLYWHEEL»(ref-275841-S29475999102007122900000) .
4. Carefully prise out the seal using a screwdriver.

Scheme 251

Scheme 252

1. Clean the sealing surfaces of gasket residue.
2. Position the «83 94 975 FITTING TOOLS, REAR CRANKSHAFT SEAL»(ref-275839-S24388749492007122900000) protective collar on the crankshaft. Lubricate the new sealing ring with non-acidic Vaseline and position it on the fitting tool.
3. Position the fitting tool on the crankshaft. Drive in the sealing ring with the shaft and the narrow guide sleeve until it is flush with the timing cover. Remove the tool.
4. Fit «FLYWHEEL»(ref-275841-S29475999102007122900000) or driver plate with new bolts.
5. Fit the pressure plate and the clutch drive plate, see «CLUTCH ASSEMBLY»(ref-275841-S00742841292007122900000) .
6. Fit the gearbox, see appropriate MANUAL GEARBOX article.
7. Check the oil level in the engine. Top up as necessary.

Scheme 253

When setting the balancer shaft chain loop, the marks on the cogs must be aligned with the marks on the block. The chain is adjusted (Scheme 253)and when the pulley is zeroed with cylinder 1 in the top dead center.

Scheme 254

Scheme 255

Scheme 256

Scheme 257

Scheme 258

Scheme 259

Scheme 260

1. Raise the car.
2. Remove the front right wheel.
3. Remove the right wing liner and raise the car further. CV: Remove «CHASSIS REINFORCEMENT, FRONT SUBFRAME, CV, PETROL»(ref-275876-S05650643942007122900000) .
4. Place a receptacle under the car and drain the engine oil.
5. Fit the oil plug with a new seal and lower the car.
6. Remove the upper engine cover.
7. Remove the dipstick.
8. Remove the dipstick tube fixing bolt.
9. Unplug and detach the connector from the mounting on the dipstick.
10. Undo the clip and pull up the dipstick from the oil sump.
11. Raise the car and undo the connector to the oil level sensor. (Only on engine variant B207R)
12. Remove the lower charge air pipe.
13. Remove the lower A/C compressor retaining bolt.
14. Up to M04 inclusive: Undo the rear torque arm bolt and remove the front bolts.
15. Remove the oil pan retaining bolts.
16. Place a screwdriver between the oil pan and the timing cover by the A/C compressor and carefully prise loose the oil sump.

Scheme 261

Scheme 262

Scheme 263

Scheme 264

Scheme 265

Scheme 266

Scheme 267

1. Clean the sealing surfaces on the engine block and the sump. Remove any impurities in the oil sump.
2. Apply a 2 mm thick bead of 90 543 772 Silicone flange sealant on the oil sump sealing surface and on the connection to the oil strainer suction pipe.
3. Fit the oil sump carefully so that the sealing compound is not disturbed. Tightening torque, oil sump 22 Nm (16 lbf ft). Tightening torque, bolts in gearbox 70 Nm (52 lbf ft).
4. Up to M04 inclusive: Fit the front torque arm bolts to the oil sump and tighten the rear bolt. Tightening torque, front bolts 37 Nm (27 lbf ft). Tightening torque, rear bolt 70 Nm + 90° (52 lbf ft + 90°)
5. Fit the lower A/C compressor retaining bolt. Tightening torque 24 Nm (18 lbf ft).
6. Replace the charge air pipe.
7. Plug in the oil level sensor connector.
8. Fit the oil plug with a new O-ring. Tightening torque 25 Nm (18 lbf ft). CV: Fit «CHASSIS REINFORCEMENT, FRONT SUBFRAME, CV, PETROL»(ref-275876-S05650643942007122900000) .
9. Fit a new fastening clip on the connector.
10. Lower the car slightly and fit the right wing liner.
11. Fit the front right wheel and lower the car to the floor. See «WHEELS»(ref-275839-S31569052022007122900000) . Tightening torque 110 Nm (81 lbf ft)
12. Remove the connector's fastening clip and fit the dipstick tube with new O-rings lubricated with Vaseline, Kluber Syntheso Pro AA2.
13. Fasten the connector clip to the dipstick. Plug in the connector.
14. Fit the ventilation line clip to the dipstick.
15. Fit the dipstick.
16. Fill with engine oil as specified, see «RECOMMENDED OIL QUALITY»(ref-275836-S39457799062007122900000) .
17. Connect an exhaust extractor and start the engine. Switch off the engine and wait 2-5 minutes. Check the oil level and adjust as necessary.
18. Replace the upper engine cover.

Checks

1. Check for oil leaks on top of and underneath the engine/gearbox and the steering hydraulic system. Check especially around rotating components such as drive shafts. Check for leaking coolant or other fluids.

Scheme 268

1. Raise the car and undo the front part of the right wing liner. Bend out the wing liner.
2. Inspect the belt for damage or cracks. Make sure the markings on the belt tensioner are in their correct positions. Change if necessary, see «DRIVE BELT, AUXILIARY EQUIPMENT (MULTIGROOVE)»(ref-275839-S01535371252007122900000) .
3. Fit the screws and nut for the right wing liner.
4. Lower the car.

Scheme 269

Scheme 270

Scheme 271

Scheme 272

1. Place drapes over the wings to keep the paintwork clean and protect it from damage. Raise the car.
2. CV: Remove the cross brace. See «CHASSIS REINFORCEMENT, FRONT SUBFRAME, CV, PETROL»(ref-275876-S05650643942007122900000)
3. Fit «83 96 152 CENTERING TOOL, POWERTRAIN»(ref-275839-S24833006412007122900000) on the subframe. See also «CENTERING TOOL, ENGINE AND SUBFRAME»(ref-275839-S09940813002007122900000) .
4. Lower the car.
5. Remove the battery.
6. Remove the battery tray.
7. Remove the ground cable from the engine mounting.
8. Remove the engine pad bolts from the gearbox bracket.
9. Remove the bolts in the gearbox bracket. Lift out the bracket.
10. Remove the engine pad bolts from the body.
11. Remove the engine pad.

Scheme 273

Scheme 274

Scheme 275

Scheme 276

1. Fit the engine pad into place. Tighten. Tightening torque 15 Nm + 30° (11 lbf ft + 30°)
2. Fit the gearbox bracket. Tightening torque Nm + 90° (lbf ft +90°)
3. Fit the engine pad bolts to the bracket. Tightening torque 70 Nm + 45° (52 lbf ft + 30°)
4. Fit the ground cable to the engine pad.
5. Fit the battery shelf and the battery.
6. Raise the car and remove «83 96 152 CENTERING TOOL, POWERTRAIN»(ref-275839-S24833006412007122900000) from the subframe.
7. CV: Fit the cross brace. See «CHASSIS REINFORCEMENT, FRONT SUBFRAME, CV, PETROL»(ref-275876-S05650643942007122900000) .
8. Lower the car and remove the wing protectors.
9. Carry out «PROCEDURES AFTER DISCONNECTING THE BATTERY»(ref-275839-S39476668922007122900000)

Scheme 277

Scheme 278

Scheme 279

1. Cover the wings and raise the car.
2. CV: Remove «CHASSIS REINFORCEMENT, FRONT SUBFRAME, CV, PETROL»(ref-275876-S05650643942007122900000) .
3. Open the power steering pipe's clips on the subframe.
4. Fit «83 96 152 CENTERING KIT, ENGINE TO THE SUBFRAME»(ref-275839-S24833006412007122900000) . See also «CENTERING TOOL, ENGINE AND SUBFRAME»(ref-275839-S09940813002007122900000) .
5. Lower the car.
6. Remove the turbocharger intake hose, unplug the mass air flow sensor connector.
7. Remove the air cleaner cover and the air cleaner. Detach the inlet hose and remove the air cleaner casing.
8. Remove the engine pad from the body and bracket.

Scheme 280

Scheme 281

Scheme 282

1. Fit and adjust the engine pad to the body. Tighten the bolts between the engine pad and the bracket. The engine pad and bracket should be aligned with each other. IMPORTANT: Engine mountings should not lie against the engine brackets. Tightening torque, body 40 Nm +60° (30 lbf ft +60°) Tightening torque, bracket 70 Nm +60° (52 lbf ft +60°)
2. Fit the air filter housing and intake hose. Fit the air filter and filter housing lid.
3. Plug in the mass air flow sensor connector and fit the turbocharger intake hose.
4. Raise the car, remove «83 96 152 CENTERING KIT, ENGINE»(ref-275839-S24833006412007122900000) .
5. Fit the power steering pipe to the subframe.
6. CV: Fit «CHASSIS REINFORCEMENT, FRONT SUBFRAME, CV, PETROL»(ref-275876-S05650643942007122900000)
7. Lower the car and remove the wing protectors.

Scheme 283

Scheme 284

1. Remove «TIMING COVER»(ref-275839-S23616829302007122900000) .
2. Remove the oil pump bolts. Lift off the cover and take out the pinions. IMPORTANT: Note the marks on the gears.
3. Remove the oil pressure valve. Maintain a grip when unscrewing the plug so that it does not fall away.
4. Remove the spring and the piston.

Scheme 285

Scheme 286

Scheme 287

1. Fit the oil pump pinions. The markings on the pinions must be turned to the timing cover. Lubricate the pinions with engine oil.
2. Fit the oil pump cover. Tightening torque 6 Nm (4 lbf ft)
3. Fit the oil pressure valve with the piston and the spring. Replace the gasket. Tightening torque 40 Nm (29 lbf ft)
4. Fit «TIMING COVER»(ref-275839-S23616829302007122900000) .

Scheme 288

1. Remove the right-hand «DRIVE SHAFTS»(ref-275844-S02462561152007122900000) .
2. Remove the oil pressure valve. Maintain a grip when unscrewing the plug so that it does not fall away.
3. Remove the spring and the piston.

Scheme 289

1. Fit the oil pressure valve with the piston and the spring. Replace the gasket.
2. Fit the right-hand «DRIVE SHAFTS»(ref-275844-S02462561152007122900000) . Tightening torque 40 Nm (29 lbf ft)

Procedures after disconnecting the battery

1. Clear diagnostic trouble codes in all systems. IMPORTANT: Some diagnostic trouble codes can be generated if there is a voltage drop. These diagnostic trouble codes can be ignored and will not be regenerated after deletion.
2. Set the clock as follows: Turn the ignition key to the ON position. Press CUSTOMIZE on SIDC (SID control panel). Turn the INFO knob until the displays shows "Clock/Alarm". Press to confirm "OK". Turn the INFO knob to "Set Clock". Press "OK". Turn the INFO knob to "Manual" or "RDS adjust" and set the correct time. Press "OK".
3. Set the date as follows: Turn the ignition key to the ON position. Turn the INFO knob to "DATE". Press the INFO knob until the display shows "YEAR 2000". Turn the INFO knob to the correct year. Press to confirm "OK". Turn the INFO knob to the correct month. Press "OK". Turn the INFO knob to the correct date. Press "OK". IMPORTANT: Draw the customer's attention to the fact that all remote controls must be synchronized by placing the key/keys in the ignition lock. If this is not done, the remote control will not work.
4. Synchronize the remote control's code by inserting the key in the ignition switch. WARNING: The trap protection is not active until the window lifters have been calibrated after a power failure.
5. Cars with pinch protection: Program the pinch protection, see «CALIBRATION OF PINCH PROTECTION»(ref-275880-S25624593362007122900000) .

Scheme 290

Scheme 291

Scheme 292

Scheme 293

Scheme 294

1. Remove «CYLINDER HEAD»(ref-275839-S38563318952007122900000) . Fit the right-hand engine mounting. Following which, remove the jack and wood block under the oil sump.
2. Pull up the dipstick pipe from the oil sump.
3. Remove any burrs and carbon deposits from the tops of the cylinders.
4. Raise the car.
5. Place a receptacle under the car and drain the engine oil.
6. Fit the oil plug with a new seal. Tightening torque 25 Nm (18 lbf ft)
7. Unplug the oil level sensor connector.
8. Remove the lower fixing bolt for the A/C compressor.
9. Up to M04 inclusive: Undo the rear torque arm bolt and remove the front bolts.
10. Remove the oil pan fixing bolts.
11. Place a screwdriver between the pan and the timing cover at the AC compressor, and carefully prise the oil sump loose.
12. Remove the connecting rods' bearing caps. Push the pistons and connecting rods up out of the cylinder bores.
13. Lower the car and carefully lift out the pistons. Note the marking on the pistons and connecting rods so that they can be refitted in their original positions. Fit the bearing shells and bearing caps loosely on the connecting rods so that the parts do not get mixed up.
14. Remove the piston rings.
15. Clean any carbon and oil from the piston ring grooves in the pistons.

Scheme 295

Scheme 296

Scheme 297

Scheme 298

Scheme 299

Scheme 300

Scheme 301

Scheme 302

1. Fit the oil scraper ring. IMPORTANT: Ensure that the spring openings of the upper and lower rings on the three-part oil scraper ring are not located in front of each other.
2. Use a piston ring expander when fitting the rings onto the piston.
3. The compression rings must be turned with the marking "TOP" facing upward. IMPORTANT: The lower compression ring is black and the upper one is silver.
4. Oil the piston and ring before fitting. Turn the compression rings so that the rings' openings are displaced 180° from each other and aligned with the gudgeon pin ends.
5. Oil the piston rings, bearings and cylinder.
6. Fit the pistons using «83 95 113 PISTON FITTING TOOL»(ref-275839-S16145295932007122900000) . The arrows on the pistons must point towards the timing chain.
7. Raise the car.
8. Fit the bearing caps with bearing shells. The outer bevelling on the connecting rod and bearing cap must butt up against each other. Tightening torque 25 Nm + 100° (18 lbf ft + 100°)
9. Clean the engine block and sump sealing surfaces. Remove any contaminants in the oil sump.
10. Apply a 2 mm thick bead 83 95 691 Flange sealant to the oil sump sealing surface and to the oil strainer suction pipe's connection.
11. Carefully fit the oil sump so that the sealant is not scraped off. Tightening torque, oil sump 22 Nm (16 lbf ft) (11a) Tightening torque, bolts in gearbox 70 Nm (52 lbf ft)
12. Up to M04 inclusive: Fit the front torque arm bolts to the oil sump and tighten the rear bolt. Tightening torque, front bolts 37 Nm (27 lbf ft) Tightening torque, front bolts 70 Nm + 90° (52 lbf ft + 90°)
13. Fit the A/C compressor lower fixing bolt. Tightening torque 24 Nm (18 lbf ft)
14. Plug in the oil pressure switch connector.
15. Lower the car.
16. Fit the dipstick pipe in the oil sump with a new O-ring, greased with 30 06 665 Vaseline.
17. Place a jack with wood block under the oil sump and relieve the load from the right-hand engine pad. Remove the right-hand engine mounting.
18. Fit «CYLINDER HEAD»(ref-275839-S38563318952007122900000) .
19. Fill with engine oil.

Scheme 303

Scheme 304

1. Raise the car. IMPORTANT: The flexible bellow on the front section of the exhaust system must not be bent more than 5° from its neutral line. This means that if the front exhaust system is left hanging freely, it must not be bent more than by its own weight. If the strain on the pipe is too great, its component parts will be permanently deformed. This can cause noise, leaks and eventually complete breakdown.
2. Remove the nuts from the front exhaust pipe on the catalytic converter. Take the strain off the front section with «83 95 212 STRAP»(ref-275839-S21654658182007122900000) .
3. Remove the rear torque arm bracket.
4. Remove the rear torque arm.

Scheme 305

Scheme 306

1. Fit the rear torque arm. Tightening torque 60 Nm (44 lbf ft)
2. Fit the rear torque arm bracket. Tightening torque 80 Nm (59 lbf ft).
3. Fit the rear exhaust pipe. Remove the strap. Tightening torque 25 Nm (18 lbf ft).
4. Lower the car.

Scheme 307

Scheme 308

1. Raise the car.
2. Remove the front torque arm. Auto: Man

Scheme 309

Scheme 310

1. Fit the front torque arm. Tightening torque, nut and bolt 60 Nm +90° (44 lbf ft +90°) Tightening torque bolt to gearbox 80 Nm (59 lbf ft) Auto: Man
2. Lower the car.

Scheme 311

Scheme 312

1. Fit the tool on the trolley lifts. Pay attention to the positioning of the column and the locating pins.
2. Position the tool under the car's subframe.

Scheme 313

Scheme 314

Scheme 315

Scheme 316

1. Petrol B207 and B284: Install «83 96 152 KIT, CENTERING TOOL ENGINE»(ref-275839-S24833006412007122900000) on 83 96 145 Centering tool, subframe - engine with 83 96 368 Supplement kit for centering fixture. Pay attention to bolt location. The distance from the washer to the slot in the threads is different on the two short sleeves. Fit only sleeve A (Scheme 356) Use Thread locking adhesive, Loctite 270 on the sleeve. B284: Use 32 025 059 Support. Petrol 1.8 XE: Use 83 96 145 Centering tool, subframe - engine with support from 83 96 368 Supplement kit for centering fixture. Diesel: Fit 32 025 007 Installation fixture on 83 96 145 Centering tool, subframe - engine with support from 83 96 368 Supplement kit for centering fixture. CV: In order to fit 83 96 145 Centering tool, subframe - engine to the subframe, a recess must be made in one of the fixture "legs" shown below.

Scheme 317

1. Fine-tune the position of the power train using the adjuster screws. The left and right engine brackets should make the same amount of contact with each engine pad. IMPORTANT: Engine mountings should not lie against the engine brackets.
2. Tighten the bolts to the prescribed torque.

Scheme 318

1. Remove «CAMSHAFT COVER WITH GASKET»(ref-275839-S30583539642007122900000)
2. Remove «TIMING COVER»(ref-275839-S23616829302007122900000)
3. Fit the crankshaft pulley.
4. Lower the car and zero the engine by turning the crankshaft in the direction of rotation of the engine until the marking on the crankshaft pulley is aligned with the marking on the timing cover. The cam lobes on cylinder 1 intake and exhaust camshafts should be pointing up/in. (A)
5. Remove the chain tensioner (A). Use «83 96 129 OIL FILTER TOOL, B207, AND CAMSHAFT DRIVE CHAIN TENSIONER»(ref-275839-S00840118692007122900000) .
6. Remove the lock ring (A) from the chain tensioner and remove the piston.
7. Remove the plug (A) from the cylinder housing.
8. Remove the upper bolt (B) to the timing chain guide at the inlet side.
9. Remove the upper timing chain guide rail (C).
10. Remove the lower bolt to the chain guide (A). Detach the lower section of the chain.
11. Remove the camshaft pinions (B). Use a wrench to grip the camshaft flats when the bolts are loosened. Lift up the chain.
12. Remove the tensioner guide (C) by lifting it up. Inspect the condition of the guide. Replace if necessary.

Scheme 319

1. Clean all sealing surfaces.
2. Clean the camshaft and pinion contact surfaces (A) from oil and grease.
3. Fit the tensioner guide (A).
4. Lay the chain on the intake sprocket and lower the chain. Fit the sprocket on the camshaft and tighten the bolt (B).
5. Raise the car.
6. Fit the chain on the crankshaft sprocket and fit the chain guide. Fit the lower bolt (C). Tightening torque 10 Nm (7 lbf ft)
7. Lower the car.
8. Fit the exhaust sprocket and tighten the bolt (D).
9. Fit the upper bolt. Fit the plug on the cylinder head (E).
10. Turn the camshaft drive tensioner clockwise with a screwdriver until it engages in the tensioned position (A).
11. Place the plunger in the chain tensioner sleeve. Fit the circlip (A) and check that it is fitted correctly in the groove. NOTE: Check that the O-ring and gasket are intact. If damaged, replace the chain tensioner assembly.
12. Fit the chain tensioner (A). Tightening torque 75 Nm (55 lbf ft)
13. Release/activate the chain tensioner by carefully pressing on the timing chain or chain guide (as shown in the illustration). Use a screwdriver (A). Check that the tensioner has released.
14. Fit «TIMING COVER»(ref-275839-S23616829302007122900000) .
15. Remove the exhaust camshaft and intake camshaft bearing caps no. 2 and no. 7. Position «83 96 046 ADJUSTMENT TOOL, CAMSHAFT (B207 150-175 HP)»(ref-275839-S25707063912007122900000) and «83 96 079 ADJUSTMENT TOOL, CAMSHAFT (B207 210 HP)»(ref-275839-S42279817962007122900000) by manually pressing the tools down onto the camshafts without tightening the bolts. Turn the camshaft until the tool aligns with the spanner on the camshaft flats. Tighten the adjustment tools' bolts (A). Tightening torque 10 Nm (7 lbf ft)
16. Check that the markings on the crankshaft pulley and the timing cover are aligned. Tighten the camshaft gears a first time. Use a wrench to grip the camshaft flats (A). Tightening torque 30 Nm (22 lbf ft)
17. Remove the adjustment tools and fit the bearing caps (B). Tightening torque 8 Nm (6 lbf ft)
18. Continue to tighten the camshaft gears to the final torque. Use a wrench to grip the camshaft flats (A). Tightening torque 85 Nm + 30° (63 lbf ft +30°)
19. Turn the crankshaft 2 rotations in the engine's direction of rotation until the markings on the crankshaft pulley and the timing cover are aligned. Remove the bearing caps and refit «83 96 046 ADJUSTMENT TOOL, CAMSHAFT (B207 150-175 HP)»(ref-275839-S25707063912007122900000) and «83 96 079 ADJUSTMENT TOOL, CAMSHAFT (B207 210 HP)»(ref-275839-S42279817962007122900000) to check that the camshaft setting is correct. Remove the adjustment tools and fit the bearing caps. Tightening torque 8 Nm (6 lbf ft)
20. Fit the upper timing chain guide rail (C).
21. Fit «CAMSHAFT COVER WITH GASKET»(ref-275839-S30583539642007122900000)
22. Lower the car completely.
23. Check engine oil level. Top up as necessary.

Scheme 320

1. Remove «TIMING CHAIN AND CAMSHAFT SPROCKET»(ref-275839-S00114508472007122900000) .
2. Remove the chain tensioner. Remove the chain tensioner (A).

1. Fit the chain tensioner. Load the tensioner by pressing in the plunger and turning to the right. Secure with tool «83 96 392 LOCK PIN (A)»(ref-275839-S15988022542007122900000) .
2. Fit the chain tensioner screws (A). Use Thread locking adhesive, Loctite 270 Tightening torque 10 Nm (7 lbf ft)
3. Remove the tool from the tensioner. Press the tensioner guide rail to check that backward movement of the plunger is prevented.
4. Fit «TIMING CHAIN AND CAMSHAFT SPROCKET»(ref-275839-S00114508472007122900000) .

Scheme 321

1. Remove «CAMSHAFT COVER WITH GASKET»(ref-275839-S30583539642007122900000)
2. Remove the upper chain guide (A).

1. Fit the upper chain guide (A).
2. Fit «CAMSHAFT COVER WITH GASKET»(ref-275839-S30583539642007122900000)

1. Clean all sealing surfaces.
2. Clean the camshaft and pinion contact surfaces (A) from oil and grease.
3. Fit the tensioner guide (A).
4. Lay the chain on the intake sprocket and lower the chain. Fit the sprocket on the camshaft and tighten the bolt (B).
5. Raise the car.
6. Fit the chain on the crankshaft sprocket and fit the chain guide. Fit the lower bolt (C). Tightening torque 10 Nm (7 lbf ft)
7. Lower the car.
8. Fit the exhaust sprocket and tighten the bolt (D).
9. Fit the upper bolt. Fit the plug on the cylinder head (E).
10. Turn the camshaft drive tensioner clockwise with a screwdriver until it engages in the tensioned position (A).
11. Place the plunger in the chain tensioner sleeve. Fit the circlip (A) and check that it is fitted correctly in the groove. NOTE: Check that the O-ring and gasket are intact. If damaged, replace the chain tensioner assembly.
12. Fit the chain tensioner (A). Tightening torque 75 Nm (55 lbf ft)
13. Release/activate the chain tensioner by carefully pressing on the timing chain or chain guide (as shown in the illustration). Use a screwdriver (A). Check that the tensioner has released.
14. Fit «TIMING COVER»(ref-275839-S23616829302007122900000) .
15. Remove the exhaust camshaft and intake camshaft bearing caps no. 2 and no. 7. Position «83 96 046 ADJUSTMENT TOOL, CAMSHAFT (B207 150-175 HP)»(ref-275839-S25707063912007122900000) and «83 96 079 ADJUSTMENT TOOL, CAMSHAFT (B207 210 HP)»(ref-275839-S42279817962007122900000) by manually pressing the tools down onto the camshafts without tightening the bolts. Turn the camshaft until the tool aligns with the spanner on the camshaft flats. Tighten the adjustment tools' bolts (A). Tightening torque 10 Nm (7 lbf ft)
16. Check that the markings on the crankshaft pulley and the timing cover are aligned. Tighten the camshaft gears a first time. Use a wrench to grip the camshaft flats (A). Tightening torque 30 Nm (22 lbf ft)
17. Remove the adjustment tools and fit the bearing caps (B). Tightening torque 8 Nm (6 lbf ft)
18. Continue to tighten the camshaft gears to the final torque. Use a wrench to grip the camshaft flats (A). Tightening torque 85 Nm + 30° (63 lbf ft +30°)
19. Turn the crankshaft 2 rotations in the engine's direction of rotation until the markings on the crankshaft pulley and the timing cover are aligned. Remove the bearing caps and refit «83 96 046 ADJUSTMENT TOOL, CAMSHAFT (B207 150-175 HP)»(ref-275839-S25707063912007122900000) and «83 96 079 ADJUSTMENT TOOL, CAMSHAFT (B207 210 HP)»(ref-275839-S42279817962007122900000) to check that the camshaft setting is correct. Remove the adjustment tools and fit the bearing caps. Tightening torque 8 Nm (6 lbf ft)
20. Fit the upper timing chain guide rail (C).
21. Fit «CAMSHAFT COVER WITH GASKET»(ref-275839-S30583539642007122900000)
22. Lower the car completely.
23. Check engine oil level. Top up as necessary.

Scheme 322

Petrol Engine

The engine is a fluid-cooled, 4-cylinder, 2.0 liter petrol in-line engine of aluminum with 4 valves per cylinder, 2 overhead camshafts and 2 balancer shafts integrated in the cylinder block.

The engine with gearbox is assembled as a unit and sits transverse in the engine bay. The engine is of the cross-flow type, i.e. with inlet ducts on one side and exhaust ducts on the other side of the combustion chamber. The cylinder liner is made of steel and is pressed into the engine block. The forged, induction hardened crankshaft is mounted on five main bearings which are integrated into a common plate, known as the bed plate.

To get a low noise level and compact engine, the coolant pump drive is integrated into the balance shaft chain circuit. The power steering pump and vacuum pump for fuel pressure amplification are directly driven via the camshafts.

Scheme 323

B207L is a water-cooled, 4-cylinder, 2.0 liter petrol driven in-line engine of aluminum with 4 valves per cylinder, 2 overhead camshafts and 2 balance shafts integrated in the cylinder block. It is crossflow type, i.e. the inlet is located on one side of the combustion chamber and the exhaust on the opposite side. Steel nonexchangeable cylinder liners are pressed into the engine block. The five main bearings are integrated in one common bed plate.

For low sound levels and compact size, the coolant pump is integrated in the balancer shaft chain circuit. The power steering pump and vacuum pump are driven directly via the camshafts. The engine is transversely mounted and is inclined 10° to the rear in the engine bay. The 2-liter capacity provides high torque even at low engine speeds, which is advantageous when driving in normal traffic conditions.

Scheme 324

The balance shafts are intended to absorb vibration and second order forces from the moving parts of the engine and at the same time reduce the level of unwanted engine noise. They are driven via a separate chain circuit in the timing cover. See BALANCER SHAFTS .

Cylinder Block

The light alloy cylinder block is manufactured in one piece with press-fit cylinder bores of steel. Passageways for the lubricating system are also drilled inside the block. The main bearing caps are not separate but integrated in a common bed plate. There are two tunnels integrated in the block for the balancer shafts. Loose non-exchangeable bearing bushings are press-fitted for the inner bearing seats.

Scheme 325

The light alloy pistons have grooves for two compression rings and one oil scraper ring. The upper compression ring is plane type and nitride hardened. The lower compression ring is phosphate coated and has oil scraper properties. The oil scraper ring is in three parts and nitride hardened. The pistons are tin plated and the gudgeon pins nitride hardened. An arrow on the piston crown indicates the position for fitting (arrow pointing to camshaft drive end). It is essential that the pistons are fitted correctly because the gudgeon pin hole is offset 0.8 mm towards the exhaust side. This has been introduced to reduce the negative effect of axial forces on cylinder wear. The pistons are cooled from below with oil sprayed through a nozzle fitted in the bottom of the cylinder block.

Scheme 326

The forged alloy steel connecting rods have bushings to house the gudgeon pins. The gudgeon pin bushing and bearing shells for the connecting rod bearings are exchangeable. The gudgeon pin is floating mounted in the piston and connecting rod. The big end of the connecting rod is split during manufacture in a process where a laser first makes a notch in the goods across the hole, after which a press tool is applied to split the big end. The hole is subsequently machined to the correct dimension. This procedure provides a perfect fit between the cap and the connecting rod. The axial movement of the gudgeon pin is limited by circlips fitted into the gudgeon pin hole.

Scheme 327

The forged crankshaft has ground, induction-hardened bearing journals. This provides a hard surface to protect against wear. The crankshaft has five main bearings integrated in one common bedplate, the middle bearing acting also as thrust bearing. Passageways are drilled in the shaft for lubricating oil. All the main bearing shells are exchangeable.

Scheme 328

The precision cast light-alloy cylinder head is bolted to the cylinder block. The domed combustion chambers have 4 valves per cylinder and centrally situated spark plugs. This improves the flow of gases in the cylinders and provides more efficient combustion, making the engine more efficient. Openings for the injectors are also situated in the inlet ports to provide an optimum injection pattern.

The design allows a very shallow cylinder head, 129.0 mm, which is space-saving and low-weight.

Scheme 329

Via roller bearings, the camshafts act on rocker arms that are supported in ball cups at one end, constituting the upper end of the hydraulic valve clearance balancers, and press against the valve stems at the other end. The hydraulic valve clearance balancers maintain the clearance between the camshaft and the rocker arm/roller bearing close to zero. Consequently, they do not take part in any movement. This design requires a low level of friction for its movement. See also CAMSHAFT DRIVE .

Scheme 330

The timing cover is designed to the shape of the cylinder block. The oil pump is mounted in the timing cover.

The Saab Balancer Shaft System

Saab has utilized the principle with balancer shafts to balance the second order inertial forces. Two balancer shafts, located symmetrically and low in the sides of the cylinder block above the centre line of the crankshaft, are provided with eccentric balance weights.

The shafts are chain driven and rotate in opposite directions to each other at twice the speed of the crankshaft. The shaft balance weights are situated so that they eliminate the reciprocal forces from the piston movement described above. Thanks to their vertical location in relation to the centre line of the crankshaft, they also balance lateral forces. The torque created by the balancer shafts is adapted so that lateral gas and inertial forces are counteracted.

An absolute provision for the function of the balancer shafts is that their mounting is precisely positioned. This is why the sprockets for the exhaust and inlet sides are designed differently and are marked accordingly.

Scheme 331

Balancer Shaft Drive

The balancer shafts are chain driven from the crankshaft and the gear ratio of the shaft drive wheels is such that the balancer shafts rotate at twice the speed of the crankshaft. Since the engine is fitted with a dual mass flywheel, the pinion on the crankshaft for the balancer shaft circuit is fitted with a spring-damper hub to absorb the torsional fluctuations that can be generated in the crankshaft by the balancer shaft circuit. This hub is flexible ± 5°.

The shaft on the exhaust side rotates in the opposite direction with the water pump pinion acting as an idler wheel. The chain is guided by two fixed chain guides and an adjustable chain guide that is acted on by a tensioner. This chain tensioner operates with an opposing force made by the pressure of oil to limit the tension and thereby minimize chain wear and noise.

The coolant pump is driven by the balancer shaft chain. The pinion is mounted in the timing cover. This further reduces noise. The balancer/water pump chain circuit is inside the camshaft chain circuit.

Scheme 332

Camshafts

Then engine has twin overhead camshafts driven by a single chain with self-adjusting chain tensioner. To further reduce chain noise, the edges of the camshaft sprocket on the crankshaft are coated in rubber.

Scheme 333

The cam lobes act on the rocker arms via roller bearings mounted on the rocker arms. This eliminates the need for valve adjustment as it is achieved continuously via a hydraulic balancer under the valve rocker. The valve clearance balancer works in an oil bath and is supplied with oil via an oilway in the cylinder head. The main advantages are very low friction, quiet running and high reliability.

The inlet valves are made of steel with chromium plated stems. The exhaust valves are made of special steel and are filled with sodium, which helps to dissipate 50% of the heat through the valve stem by transporting the heat away from the valve head to the stem.

Note that before scrapping a valve, a cut must be made in the stem where the cavity for the sodium is to avoid risk of explosion.

The inlet camshaft drives the power steering pump and the exhaust camshaft the vacuum pump via direct drive.

Scheme 334

The cam chain tensioner is mounted in the cylinder head and is easily accessible for service. The tension is applied by a spring-loaded piston that keeps the slack side of the chain taut via a guide rail that is supported at the bottom. A close-stepped ratchet prevents the piston, and thereby the guide rail, from returning. The balancer shaft chain tensioner is mounted on the cylinder block inside the chain circuit cover.

The chain tensioner has tightly spaced adjustment intervals, which allows good compensation for chain wear and consequently quieter running.

Scheme 335

When setting the balancer shaft chain loop, the marks on the cogs must be aligned with the marks on the block. The chain is adjusted as shown in the diagram and when the pulley is zeroed with cylinder 1 in the top dead centre.

Scheme 336

The engine's lubrication is handled by a pressure lubricating system where the oil pressure is generated by a gear pump comprising one gear sprocket and one centre-displaced internal gear ring. The pump is located in the timing cover and is driven by the crankshaft.

The oil is sucked up from the sump via the strainer and suction pipe to the oil pump. A pressure-reducing valve in the timing cover limits oil pressure while excess oil is lead back to the suction side of the pump. The oil is then lead via a channel in the cylinder block further on to the oil filter. The engine is equipped with an oil cooler. The oil filter adapter housing contains a thermostat, which begins to open at 107 ± 2° and is fully open at 120°C, to allow the oil to circulate through the oil cooler. After filtering and, if necessary, cooling, the oil is lead out into the main channel of the cylinder block where it then branches out to all parts of the lubricating system.

When the oil pressure becomes too low, the sensor, which is located in the main oilway, will ground the electrical circuit for the warning lamp in the main instrument unit. In the oil pan is also an ENGINE OIL LEVEL SWITCH (243) (2006) or ENGINE OIL LEVEL SWITCH (243) (2007) for the oil, which indicates via SID that the oil needs to be topped up. The amount of oil then remaining in the oil pan is approx. 4 liters. The crankshaft main and big end bearings are lubricated via passageways in the block and crankshaft, while pistons and cylinder walls are lubricated by oil mist and splash in the crankcase. There is also a piston cooling nozzle fitted for each cylinder that sprays a fine jet of oil on the bottom of the piston.

The outer bearing on the exhaust side balancer shaft is supplied with oil through a drilling in the no. 1 main bearing. The inner bearing on the exhaust side balancer shaft is supplied with oil through a drilling in the no. 3 main bearing. Both balancer shaft bearings on the inlet side are supplied with oil from the main gallery. From the main gallery in the cylinder block, a rising oilway to the cylinder head also supplies oil for the camshafts and valve mechanism. Through one of the cylinder head bolt holes, oil flows through drilled passages to the camshaft bearings and valve tappets.

Scheme 337

The oil sump is adapted to the cylinder block. Sealing compound is applied directly to the flat surface of the flange.

Scheme 338

The oil filter is mounted on the left-hand side of the cylinder block and is accessible from above after removing the upper engine cover. The oil filter is insert type. In case the filter becomes blocked by dirt obstructing the flow of oil there is an overflow filter fitted in the top of the oil filter holder

Scheme 339

The engine has a belt circuit that drives the A/C compressor and generator.

The belt circuit has an automatic and self-adjusting belt tensioner for simpler service and long life. The belt tensioner comprises a powerful spring that affects the belt tension via a pulley. The belt is multigroove type.

Scheme 340

Background

The power unit is suspended from two points; one on the left-hand side at the top of the gearbox and the body, and the other on the top right of the engine and the body.

The left-hand one is rubber, while the right-hand one is a combined rubber/hydraulic design. Using a hydraulic mounting on the right-hand side reduces the vibration that arises in the drive unit due to poor road surfaces. The vibration inherent in the engine is absorbed by the rubber part of the mounting, while the hydraulic part is active when the amplitude (vibration) in the drive unit is greater. Two torque arms complete the engine suspension. These arms, one fastened to the oil pan and helper frame, and the other to the mating surface between the engine and gearbox and the helper frame, absorb the torque that is exerted on the drive unit during acceleration and retardation.

Cylinder Bore

CYLINDER BORE REFERENCE

Scheme 341

CYLINDER HEAD REFERENCE

General Data

GENERAL DATA SPECIFICATIONS

Scheme 342

The piston diameter is measured perpendicular to the piston pin and 9 mm from the piston base

PISTON SPECIFICATIONS

Pistons

Piston Class and Cylinder Travel

The pistons for B207E/B207L/B207R only have one class

The cylinders in B207E/B207L/B207R only have one class

Scheme 343

Piston Rings

PISTON SPECIFICATIONS

Scheme 344

Piston Pin

PISTON SPECIFICATIONS

Scheme 345

Connecting rod

CONNECTING ROD SPECIFICATIONS

Scheme 346

General Data B207L

GENERAL DATA SPECIFICATIONS

Crankshaft Journal Diameter B207L

CRANKSHAFT JOURNAL DIAMETER REFERENCE

Main Bearing Journal Diameter B207L

MAIN BEARING JOURNAL DIAMETER REFERENCE

Scheme 347

Scheme 348

Scheme 349

1. Inlet valves INLET VALVES REFERENCE A mm 5.9625 ± 0.0075 B mm 35.1 ± 0.15 C mm 102.27 ± 0.15 D mm 1.76 E ° 45°, 20'
2. Exhaust valves EXHAUST VALVES REFERENCE A mm 5.953 ± 0.007 B mm 30.1 ± 0.15 C mm 100.96 D mm 2.26 E ° 45° 20' WARNING: The exhaust valves are filled with salt and must not be heated to glowing else there is a risk of explosion.

Valve Guides

VALVE GUIDES REFERENCE

Play is measured with the valve disc 3 mm from the seat.

Tappets

TAPPETS REFERENCE

Valve Springs

VALVE SPRINGS REFERENCE

Scheme 350

GENERAL DATA SPECIFICATIONS

Cam Lift

CAM LIFT SPECIFICATIONS

Valve Timing

VALVE TIMING REFERENCE

B207E/L: Total valve opening duration intake and exhaust: 230°

B207R: Total valve opening duration intake: 235°, exhaust: 240°

GENERAL DATA SPECIFICATIONS

Scheme 351

DRIVE-BELT TENSION REFERENCE

Scheme 352

GENERAL DATA SPECIFICATIONS

Scheme 353

OIL PRESSURE SPECIFICATIONS

Scheme 354

ENGINE NUMBER REFERENCE

Power Train

POWER TRAIN DIMENSION TABLE

B207E

150 hp (110 kW)

240 Nm

Scheme 355

B207L

175 hp (129 kW)

265 Nm

Scheme 356

B207R

210 hp (154 kW)

300 Nm

Scheme 357

B207S

175 hp (129 kW)

265 Nm

Fuel Consumption

FUEL CONSUMPTION REFERENCE

Scheme 358

86 12 798 Toolboard T1 Service

Used together with 30 05 469 Adapter, cooling system tester

SPECIAL TOOL REFERENCE

Scheme 359

86 12 798 Toolboard T1 Service

Used together with 30 05 477 COOLING SYSTEM TESTER

Group: Engine

SPECIAL TOOL REFERENCE

Scheme 360

Group: Engine, Manual gearbox

Used together with 83 94 751 HOLDER, ENGINE

SPECIAL TOOL REFERENCE

Scheme 361

86 12 830 Toolboard T4 Manual Gearbox

Use with 83 90 858 PIN

Group: Manual gearbox

SPECIAL TOOL REFERENCE

Scheme 362

Used together with 83 90 270 SLIDING HAMMER .

SPECIAL TOOL REFERENCE

Scheme 363

Used e.g. for running fuel pump

Group: Test equipment

SPECIAL TOOL REFERENCE

Scheme 364

86 12 863 Toolboard T6 Tool Holders

Used together with 78 74 878 FLOOR STAND

Group: Engine

SPECIAL TOOL REFERENCE

Scheme 365

Group: Engine, Manual gearbox

SPECIAL TOOL REFERENCE

Scheme 366

Group: Engine

SPECIAL TOOL REFERENCE

Scheme 367

Used together with 83 94 934 FITTING KIT, REAR CRANKSHAFT SEAL, V6

86 12 798 Toolboard T1 Service

Group: Engine

SPECIAL TOOL REFERENCE

Scheme 368

Group: Engine

SPECIAL TOOL REFERENCE

Scheme 369

86 12 871 Toolboard T7 Diesel 4-cyl

Group: Engine

Reference: -977

SPECIAL TOOL REFERENCE

Scheme 370

For parting the fuel line and tank ventilation

Group: Engine

SPECIAL TOOL REFERENCE

Scheme 371

86 12 822 Toolboard T3 Engine

Color: Blue

Group: Engine

SPECIAL TOOL REFERENCE

Scheme 372

86 12 822 Toolboard T3 Engine

Color: Yellow

Group: Engine

SPECIAL TOOL REFERENCE

Scheme 373

86 12 798 Toolboard T1 Service

Group: Engine

SPECIAL TOOL REFERENCE

Scheme 374

Group: Engine

SPECIAL TOOL REFERENCE

Scheme 375

Group: Engine

SPECIAL TOOL REFERENCE

Scheme 376

86 12 798 Toolboard T1 Service

Group: Engine

SPECIAL TOOL REFERENCE

Scheme 377

Used together with 83 96 145 Centering tool, subframe - engine and 83 95 311 Trolley lift.

Group: Engine

SPECIAL TOOL REFERENCE

Scheme 378

86 12 798 Toolboard T1 Service

Group: Manual gearbox

SPECIAL TOOL REFERENCE

Scheme 379

Group: Engine

SPECIAL TOOL REFERENCE

Scheme 380

86 12 822 Toolboard T3 Engine

Group: Engine

SPECIAL TOOL REFERENCE

Scheme 381

86 12 822 Toolboard T3 Engine

Used together with 83 95 370 Handle

Group: Engine

SPECIAL TOOL REFERENCE

Scheme 382

KM-77

86 12 822 Toolboard T3 Engine

Group: Engine

SPECIAL TOOL REFERENCE

Scheme 383

86 12 855 Toolboard T5 Automatic Transmission

Group: Automatic transmission

SPECIAL TOOL REFERENCE

Scheme 384

86 12 855 Toolboard T5 Automatic Transmission

Used together with 87 91 683 PULLER

Group: Automatic transmission

SPECIAL TOOL REFERENCE

Scheme 385

For torque converter

Group: Automatic transmission

Scheme 386

86 12 798 Toolboard T1 Service

Group: Manual gearbox

SPECIAL TOOL REFERENCE

Scheme 387

KM-6282

86 12 814 Toolboard T2 Chassis-body

Group: Chassis

SPECIAL TOOL REFERENCE